Stacked integrated circuit packages that include monolithic conductive vias

ABSTRACT

Microelectronic packages are fabricated by stacking integrated circuits upon one another. Each integrated circuit includes a semiconductor layer having microelectronic devices and a wiring layer on the semiconductor layer having wiring that selectively interconnects the microelectronic devices. After stacking, a via is formed that extends through at least two of the integrated circuits that are stacked upon one another. Then, the via is filled with conductive material that selectively electrically contacts the wiring. Related microelectronic packages are also described.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority under 35 USC §119 to Korean PatentApplication No. 10-2008-0107855, filed on Oct. 31, 2008, the disclosureof which is hereby incorporated herein by reference in its entirety asif set forth fully herein.

BACKGROUND OF THE INVENTION

This invention relates to methods of packaging integrated circuits andintegrated circuits so packaged, and more particularly to methods ofstacking integrated circuits to form three-dimensional (3D)microelectronic packages and microelectronic packages so formed.

Integrated circuits are widely used in consumer, commercial and otherapplications to provide memory devices, logic devices, processordevices, sensor devices, electro-optical devices and many othermicroelectronic devices. Integrated circuits generally include thereinlarge numbers of active and passive devices. An integrated circuitgenerally includes at least one single element and/or compoundsemiconductor layer. The semiconductor layer may also include a singleelement and/or compound semiconductor substrate, and one or moreepitaxial layers. Active devices are generally formed in thesemiconductor layer. A wiring layer is also provided on thesemiconductor layer to provide a wiring pattern that is used tointerconnect the semiconductor devices that are in the semiconductorlayer and/or to provide input/output (I/O) connections to devices thatare external of the integrated circuit. The wiring layer may include oneor more wiring patterns that are insulated from one another and from thesemiconductor layer by one or more insulating layers.

The integration density of integrated circuits continues to increase, sothat more and more active and passive devices may be provided in a givenintegrated circuit. Additional integration density may also be providedby stacking integrated circuit substrates upon one another to providestacked or three-dimensional (3D) integrated circuit structures. Morespecifically, integrated circuits may be stacked upon one another,face-to-face. These stacked devices may decrease the wiring lengths andmay provide high packing density, high speed operation, low powerconsumption, low cost, and/or parallel processing. Stacked integratedcircuits generally include a conductive via that extends through a givenintegrated circuit, so that both faces of the integrated circuit may beconnected to other devices. Since integrated circuits often include asilicon semiconductor layer, these conductive vias that extend throughthe integrated circuit are often referred to as “through-silicon vias”(TSVs).

As is well known to those having skill in the art, integrated circuitsare generally fabricated as wafers, in which tens, hundreds or morechips are fabricated and then singulated into individual chips. Theactive/passive devices may be formed in the integrated circuits at thewafer stage, and the wiring layers may also be formed on thesemiconductor layer at the wafer stage. Through-silicon vias may befabricated in the integrated circuits at the wafer stage as well, priorto forming the active devices therein and/or after forming the activedevices therein. The wafers, including the through-silicon vias may thenbe bonded together and stacked.

SUMMARY OF THE INVENTION

Microelectronic packages may be fabricated, according to variousembodiments, by stacking of plurality of integrated circuits upon oneanother. A respective integrated circuit includes a semiconductor layerhaving active microelectronic devices therein and a wiring layer on thesemiconductor layer having wiring that selectively interconnects theactive microelectronic devices. After stacking, a via is formed thatextends through at least two of the plurality of integrated circuitsthat are stacked upon one another, including through the semiconductorlayers and through the wiring layers thereof. Then, after forming thevia that extends through at least two the plurality of integratedcircuits that are stacked upon one another, the via is filled withconductive material that selectively electrically contacts the wiring.In some embodiments, the wiring includes input/output pads and the viais filled to selectively electrically contact the input/output pads.Accordingly, vias are formed and filled after stacking the integratedcircuits upon one another, which can thereby reduce the cost and/orcomplexity of the fabrication process.

In some embodiments, the via is a linear via that extends through atleast two of the plurality of integrated circuits including through thesemiconductor layers and through the wiring layers thereof, to define acontinuous sidewall in the plurality of integrated circuits. Thesidewalls of the semiconductor layers are then recessed relative to thewiring layers. In other embodiments, an insulating layer is formed onthe recessed sidewalls of the semiconductor layers. The insulating layermay be formed on the recessed sidewalls of the semiconductor layers byforming an insulating layer on the sidewalls of the wiring layers and onthe recessed sidewalls of the semiconductor layers, and then removingthe insulating layer from the sidewalls of the wiring layers. Morespecifically, the sidewalls of the semiconductor layers may be recessedrelative to the wiring layers by wet etching the semiconductor layersand wiring layers using an etchant that selectively etches thesemiconductor layers relative to the wiring layers. Moreover, theinsulating layer may be formed using low-temperature plasma oxidedeposition.

In still other embodiments, stepped vias may be formed and filled. Inparticular, in some embodiments, a first and a second integrated circuitare stacked upon one another, such that the wiring layer of the firstintegrated circuit is adjacent the substrate of the second integratedcircuit. A stepped via is then formed that recesses a sidewall of thesemiconductor layer of the second integrated circuit relative to asidewall of the wiring layer of the first integrated circuit, so as toexpose a portion of the wiring of the first integrated circuit. The viais then filled with conductive material that selectively electricallycontacts the portion of the wiring of the first integrated circuit. Insome of these embodiments, the wirings of the first and secondintegrated circuits are laterally offset from one another, so that thestepped via may be formed by etching the wiring layer of the second andfirst integrated circuits using the laterally offset wiring of the firstintegrated circuit as an etch mask. Moreover, in some of these offsetvia embodiments, an insulating layer may be formed on the sidewalls ofthe stepped via that exposes the portion of the wiring of the firstintegrated circuit. The insulating layer maybe formed using lowtemperature plasma oxide deposition and multiple masking steps.

The integrated circuits may be stacked on one another by bonding theintegrated circuits to one another. In some embodiments, direct bondingof the plurality of integrated circuits may be used, for example byforming a direct oxygen bond between adjacent faces of the integratedcircuits. The direct bonding may avoid the use of a glue layer betweenthe adjacent faces of the integrated circuits, in some embodiments. Inother embodiments, a glue layer may be used.

In still other embodiments, the via extends through at least two of theplurality of integrated circuits that are stacked upon one another, butonly extends partially through an outermost semiconductor layer of afirst one of the plurality of integrated circuits. After filling thevia, the outermost semiconductor layer of the first one of the pluralityof integrated circuits is then thinned to expose the via that is filled.

In still other embodiments, the stacking, forming a via and filling thevia may be performed on the integrated circuits at a wafer level. Thus,in some embodiments, a plurality of integrated circuit wafers arestacked upon one another. Then, a via that extends through at least twoof the plurality of integrated circuit wafers is formed. Linear vias,stepped vias, direct bonding and other techniques that were describedabove may be employed. After filling the via, the stacked integratedcircuit wafers having the filled via are diced.

Microelectronic packages according to various embodiments include aplurality of integrated circuits that are stacked upon one another,wherein a respective integrated circuit includes a semiconductor layerincluding active microelectronic devices therein, and a wiring layer onthe semiconductor layer having wiring that selectively interconnects theactive microelectronic devices. A monolithic conductive via extendsthrough the plurality of integrated circuits including through thesemiconductor layers and through the wiring layers thereof. Themonolithic conductive via selectively electrically contacts the wiring.

In some embodiments, the semiconductor layers include recessed sidewallsrelative to the wiring layers, and an insulating layer is providedbetween the recessed sidewalls and the monolithic conductive via. Inother embodiments, the monolithic conductive via selectivelyelectrically contacts the wiring at the wiring layer sidewalls. In yetother embodiments, a sidewall of a semiconductor layer of a secondintegrated circuit is recessed relative to a sidewall of a wiring layerof a first integrated circuit, so as to expose a portion of the wiringlayer of the first integrated circuit, and a stepped monolithicconductive via electrically contacts the portion of the wiring layer ofthe first integrated circuit. An insulating layer also may be providedbetween the sidewalls of the first and second integrated circuits andthe monolithic conductive via. The integrated circuits may be directlyattached to one another, for example by oxygen bonds and without anintervening glue layer. The integrated circuits may be integratedcircuit chips, or integrated circuit wafers, and the vias mayselectively interconnect input/output pads thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a microelectronic package accordingto various embodiments, including a linear monolithic conductive via.

FIG. 2 is a cross-sectional view of a microelectronic package accordingto various embodiments, including a stepped monolithic conductive via.

FIGS. 3A-3G are perspective views of microelectronic packages accordingto various embodiments during intermediate fabrication steps accordingto various embodiments.

FIGS. 4A-4F are cross-sectional views of microelectronic packages thatinclude linear monolithic conductive vias according to variousembodiments during intermediate fabrication steps according to variousembodiments.

FIGS. 5A-5B are cross-sectional views of other microelectronic packagesthat include linear monolithic conductive vias according to variousembodiments during intermediate fabrication steps according to variousother embodiments.

FIGS. 6A-6B are cross-sectional views of yet other microelectronicpackages that include linear monolithic conductive vias according tovarious embodiments during intermediate fabrication steps according toyet other various embodiments.

FIGS. 7A-7E are cross-sectional views of still other microelectronicpackages that include linear monolithic conductive vias according tovarious embodiments during intermediate fabrication steps according tostill other embodiments.

FIGS. 8A-8E are cross-sectional views of microelectronic packages thatinclude stepped vias according to various embodiments duringintermediate fabrication steps according to various embodiments.

FIGS. 9A-9C are cross-sectional views of other microelectronic packagesthat include stepped vias according to various embodiments duringintermediate fabrication steps according to still other embodiments.

FIG. 10 is a cross-sectional view of a microelectronic package accordingto still other embodiments of the invention.

FIG. 11-12 are block diagrams of electronic systems that can usemicroelectronic packages according to various embodiments.

DETAILED DESCRIPTION

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which various embodiments areshown. However, this invention should not be construed as limited to theembodiments set forth herein. Rather, these embodiments are provided sothat this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art. In thedrawings, the thickness of layers and regions may be exaggerated forclarity. Like numbers refer to like elements throughout. As used hereinthe term “and/or” includes any and all combinations of one or more ofthe associated listed items and may be abbreviated as “/”.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a,” “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises,”“comprising,” “having,” “having,” “includes,” “including” and/orvariations thereof, when used in this specification, specify thepresence of stated features, regions, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, regions, steps, operations, elements,components, and/or groups thereof.

It will be understood that when an element such as a layer or region isreferred to as being “on” or extending “onto” another element (orvariations thereof), it can be directly on or extend directly onto theother element or intervening elements may also be present. In contrast,when an element is referred to as being “directly on” or extending“directly onto” another element (or variations thereof), there are nointervening elements present. It will also be understood that when anelement is referred to as being “connected” or “coupled” to anotherelement (or variations thereof), it can be directly connected or coupledto the other element or intervening elements may be present. Incontrast, when an element is referred to as being “directly connected”or “directly coupled” to another element (or variations thereof), thereare no intervening elements present.

It will be understood that, although the terms first, second, etc. maybe used herein to describe various elements, components, regions, layersand/or sections, these elements, materials, regions, layers and/orsections should not be limited by these terms. These terms are only usedto distinguish one element, material, region, layer or section fromanother element, material, region, layer or section. Thus, a firstelement, material, region, layer or section discussed below could betermed a second element, material, region, layer or section withoutdeparting from the teachings of the present invention.

Relative terms, such as “lower”, “back”, and “upper” may be used hereinto describe one element's relationship to another element as illustratedin the Figures. It will be understood that relative terms are intendedto encompass different orientations of the device in addition to theorientation depicted in the Figures. For example, if the structure inthe Figure is turned over, elements described as being on the “backside”of substrate would then be oriented on “upper” surface of the substrate.The exemplary term “upper”, can therefore, encompasses both anorientation of “lower” and “upper,” depending on the particularorientation of the figure. Similarly, if the structure in one of thefigures is turned over, elements described as “below” or “beneath” otherelements would then be oriented “above” the other elements. Theexemplary terms “below” or “beneath” can, therefore, encompass both anorientation of above and below. However, as used herein, and asconventionally used, the “vertical” direction is generally orthogonal tothe face of the substrate regardless of its orientation, whereas the“horizontal” direction is generally parallel to (extending along) theface of the substrate. Moreover, as used herein, “monolithic” meansconstituting one undifferentiated whole. Thus, a monolithic conductivevia means a conductive via that is fabricated as one single structureand constitutes one undifferentiated whole, without scams or otherinterrupting structures therein.

Embodiments of the present invention are described herein with referenceto cross section and perspective illustrations that are schematicillustrations of idealized embodiments of the present invention. Assuch, variations from the shapes of the illustrations as a result, forexample, of manufacturing techniques and/or tolerances, are to beexpected. Thus, embodiments of the present invention should not beconstrued as limited to the particular shapes of regions illustratedherein but are to include deviations in shapes that result, for example,from manufacturing. For example, a region illustrated or described asflat may, typically, have rough and/or nonlinear features. Moreover,sharp angles that are illustrated, typically, may be rounded. Thus, theregions illustrated in the figures are schematic in nature and theirshapes are not intended to illustrate the precise shape of a region andare not intended to limit the scope of the present invention.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this invention belongs. It will befurther understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the relevant art and thepresent disclosure, and will not be interpreted in an idealized oroverly formal sense unless expressly so defined herein.

Various embodiments can provide microelectronic packages and fabricationmethods therefor, wherein wafers are stacked and bonded and thenthrough-silicon vias are collectively formed in the stacked wafers. Theconductive vias may be insulated from the semiconductor layers byproviding a selective silicon wet etch to recess the sidewalls of thesemiconductor layers, and using a low temperature plasma oxidedeposition to form an insulating layer on the recessed sidewalls of thesemiconductor layers. Thus, the monolithic conductive via may beinsulated from the semiconductor layers, but may be electricallyconnected to input/output (I/O) pads in the wiring layers. Accordingly,low cost and/or reduced complexity fabrication processes may beprovided.

FIG. 1 is a cross-sectional view of a microelectronic package accordingto various embodiments, including a linear monolithic conductive via. Asshown in FIG. 1, the microelectronic package includes three integratedcircuits 100 a, 200 and 300. Although three integrated circuits areillustrated in FIG. 1, fewer or more integrated circuits may be employedin various embodiments. Each integrated circuit includes a semiconductorlayer 110 a, 210, 310 that includes active/passive microelectronicdevices therein, and a wiring layer 120, 220, 320 on the semiconductorlayer having wiring that selectively interconnects the microelectronicdevices and that also provides input/output connections external to theintegrated circuit.

Continuing with the description of FIG. 1, each of the semiconductorlayers 110 a, 210, 310 may be a single element and/or compoundsemiconductor layer. Each semiconductor layer may also include a singleelement and/or compound bulk semiconductor substrate and one or moreepitaxial semiconductor layers. For example, a semiconductor layer mayinclude a thin semiconductor layer that is spaced apart from a substrateby an intervening insulating layer and that is fabricated, for example,using semiconductor-on-insulator (SOI) technology and/or other similartechnology. In some embodiments, the substrate may be at least partiallyremoved or thinned. As will be described in detail below, in someembodiments, the bottommost substrate may be fabricated differently thanthe remaining substrates. Accordingly, a reference number 100 a, ratherthan 100, and a reference number 110 a, rather than 110, is used in FIG.1.

From a functional standpoint, the integrated circuits 100 a, 200 or 300may include identical functionality and/or different functionality. Forexample, each of the integrated circuits 100 a, 200, 300 may be anidentical memory chip in some embodiments. However, in otherembodiments, at least some of the integrated circuits may have differentfunctionalities to operate as a processor, sensor, controller, memory,optical device, etc.

The wiring layers 120, 220, 320 may include a plurality of wiringpatterns therein that are used to selectively interconnect themicroelectronic devices in the associated semiconductor layer. Moreover,one or more of the wiring layers may also include an input/output pad130, 230, 330 that is used to provide a connection external of theintegrated circuit 100 a, 200, 300. The various wiring patterns may beinsulated from one another by inter-dielectric layers of various types.Moreover, each integrated circuit may include the same number ordifferent numbers of wiring layers.

It will also be understood that FIG. 1 may be viewed as illustratingvarious other embodiments of the invention, wherein the integratedcircuits 100 a, 200, 300 are included in a wafer prior to singulation orwherein the integrated circuits are already singulated. Thus, FIG. 1 canrepresent a plurality of stacked wafers before singulation and aplurality of stacked chips after singulation.

Continuing with the description of FIG. 1, a monolithic conductive via400 extends through the plurality of integrated circuits 100 a, 200, 300including through the semiconductor layers 110 a, 210, 310 thereof, andthrough the wiring layers 120, 220, 320 thereof. The monolithicconductive via 400 selectively electrically connects the wiring. Thus,as shown in FIG. 1, the monolithic conductive via 400 electricallycontacts the input/output pads 130, 230 and 330. It will be understood,however, that not every input/output pad that is adjacent the monolithicconductive via 400 need be electrically connected thereto. Moreover, asshown in FIG. 1, insulating layers 140, 240, 340 may be provided on atleast some of the sidewalls of semiconductor layers 110 a, 210, 310,respectively. Moreover, the sidewalls of the semiconductor layers 110 a,210, 310 may be recessed relative to the sidewalls of the wiring layers120, 220, 320. In other embodiments, however, the semiconductor layer110 a, 210 and/or 310 may be connected to the monolithic conductive via.

Embodiments of FIG. 1 include a linear monolithic conductive via 400that includes a continuous sidewall. The continuous sidewall may beorthogonal to the integrated circuit faces, as illustrated in FIG. 1,oblique to the integrated circuit faces, or curved to form an arerelative to the integrated circuit faces. In contrast, embodiments ofFIG. 2 illustrate a stepped monolithic conductive via 1400. Morespecifically, referring to FIG. 2, a plurality of integrated circuits,such as integrated circuits 1000 a and 1100, are stacked upon oneanother, wherein a respective integrated circuit includes asemiconductor layer 1010, 1110 having microelectronic devices therein,and a wiring layer 1020, 1120 on the semiconductor layer 1010, 1110,having wiring including one or more input/output pads 1030, 1130.Integrated circuits 1000 a, 1100 may include all of the variousembodiments that were described above in connection with FIG. 1. Thesemany embodiments will not be described again for the sake of brevity.

As shown in FIG. 2, the wiring layer 1020 of the first integratedcircuit 1000 a is adjacent the semiconductor layer 1110 of the secondintegrated circuit 1100. Moreover, as shown, a sidewall of the secondintegrated circuit 1100, including a sidewall of the semiconductor layer1110, is recessed relative to a sidewall of the first integrated circuit1000 a, including a sidewall of the first wiring layer 1020, by adistance D, so as to expose a portion of the wiring layer 1020 on a faceof the first integrated circuit 1100 a. More specifically, as shown, theinput/output pads 1030, 1130 of the first and second integrated circuits1000 a, 1100, respectively, are of same length L and are offset from oneanother by a distance D, in some embodiments. In other embodiments,however, they need not be the same length, so that, for example, in someembodiments, the second pad 1130 may be shorter than the first pad 1030by a distance D, or may be longer than the first pad 1030. In any event,a portion 1030 a of the wiring such as the pad 1030, is exposed on aface of the first integrated circuit 1000 a.

Still referring to FIG. 2, the monolithic conductive via 1400 is astepped monolithic conductive via 1400 that electrically contacts theportion 1030 a of the first wiring that is exposed on the face of thefirst integrated circuit 1000 a. The stepped monolithic conductive via1400 may also contact an exposed portion 1130 a of the second wiring1130 that is exposed on the face of the second integrated circuit 1100.Finally, an insulating layer 1040 also may be provided. The insulatinglayer 1040 may insulate the sidewalls of the semiconductor layers 1010,1100 and the sidewalls of the wiring layers 1020, 1120 from the steppedmonolithic conductive via 1400 in some embodiments. In otherembodiments, the insulating layer may allow electrical connectionbetween sidewalls of the wiring layers 1030, 1130 and the monolithicconductive via 1400.

It will be understood that embodiments of FIG. 2 provide a steppedmonolithic conductive via 1400 that electrically connects the wiringlayer, e.g., pads 1030, 1130, on an exposed face thereof rather than thesidewall thereof. However, in other embodiments, the stepped monolithicconductive via 1400 may electrically contact the wiring at the sidewallthereof, as was the case in FIG. 1. Moreover, embodiments of FIG. 1 mayalso provide contact between the monolithic via 400 and the face of thewiring layer 130, 230, 330, in addition to or instead of the sidewallsthereof.

FIGS. 3A-3G are perspective views of microelectronic packages accordingto various embodiments during intermediate fabrication steps accordingto various embodiments. In general, wafer bonding may take place usingan adhesive or glue layer and/or using direct wafer bonding without anintervening adhesive or glue layer.

Referring now to FIG. 3A, a semiconductor-on-insulator (SOI) wafer maybe fabricated using conventional techniques. The SOI wafer may include asemiconductor substrate 22, an insulating layer 24, a device layer 26and a wiring layer 28 that are sequentially stacked. The device layer 26may include a well region, and the wiring layer 28 may include a padtherein. The SOI wafer 20 may include a plurality of SOI chips 21. Thus,the substrate 22, insulating layer 24 and the device layer 26 mayconstitute an embodiment of a semiconductor layer.

Referring to FIG. 3B, a temporary wafer 29 is attached to the SOI wafer20. The temporary wafer 29 may be attached to the SOI wafer 20 using anadhesive. The temporary wafer 29 may be glass, plastic, semiconductorand/or other materials.

Referring to FIG. 3C, the semiconductor substrate 22 and the insulatinglayer 24 are removed from the SOI wafer 20, to form a preliminary devicewafer 20 a. The semiconductor substrate 22 and the substrate insulatinglayer 24 may be removed by wet etching and/or other processes.

Referring now to FIG. 3D, a base substrate 10 is attached to thepreliminary device substrate 20 a to form a first preliminary substratestructure 50 a. The base substrate 10 may be attached to the preliminarydevice substrate 20 a by a mechanical adhesion method and/or otherconventional techniques. A mechanical adhesion method may be used wherethe base substrate 10 and the preliminary device substrate 28 arerelatively flat. The base substrate 10 may include a semiconductor layer26 and a wiring layer 28 that are sequentially stacked. The wiring layer28 may include a pad.

As described above, the base substrate 10 may be attached to thepreliminary device substrate 20 a using direct bonding techniques thatmay include silicon direct bonding or anodic bonding. In one example ofsilicon direct bonding, two silicon wafers may be directly attached toone another by placing the wafers face-to-face and heating an oxidizingambient to create oxygen bonds therebetween. This bonding may take placewithout the need for an intervening glue layer or adhesive layer. Directwafer bonding need not be described further herein.

In other embodiments, the base substrate 10 may be attached to thepreliminary device substrate 20 a using an adhesive, glue or otherinterlayer using, for example, epoxy bonding, eutectic bonding,polyimide bonding or other direct bonding techniques, such asthermocompressive bonding, low melting temperature glass bonding and/orother techniques.

Referring now to FIG. 3E, the temporary substrate 29 is removed to forma first substrate structure 50 b. The temporary substrate 29 may beremoved, by example, by wet etching.

Referring now to FIG. 3F, another preliminary device substrate 30 a maybe prepared. This preliminary device substrate 30 a may be preparedusing the same procedures as illustrated in FIGS. 3A-3C, and may includea semiconductor layer 36, a wiring layer 38 and a temporary substrate39. Preliminary device substrate 30 a may then be attached to the firstsubstrate 50 b to form a second preliminary substrate structure 50 cusing direct bonding and/or a glue layer.

Referring to FIG. 3G, the temporary substrate 39 may be removed from thesecond preliminary structure 50 c to form a second substrate structure50 d. Thus, a substrate structure including a plurality of devicesubstrates stacked on the base substrate can be fabricated. This processcan be repeated any given number of times to produce a desired number ofintegrated circuits that are stacked on one another.

FIGS. 4A-4F are cross-sectional views of microelectronic packages thatinclude linear monolithic conductive vias according to variousembodiments during intermediate fabrication steps according to variousembodiments. Referring to FIG. 4A, a microelectronic package 50 mayinclude a plurality of integrated circuits 100, 200, 300 that arestacked upon one another. The integrated circuits 100, 200, 300 may be aplurality of wafers that are stacked on the one another or may be aplurality of chips that are stacked upon one another, as was describedabove. The first integrated circuit 110 includes a semiconductor layer112 and a device layer 120 having an input/output pad 130. The secondintegrated circuit substrate 200 includes a second semiconductor layer210 and a second wiring layer 220 including a second input/output pad230 therein. The third integrated circuit 300 includes a thirdsemiconductor layer 310 and a third wiring layer 320 including a thirdinput/output pad 330 therein. Fewer or more integrated circuits may beprovided.

The I/O pads 130, 230, 330 may be vertically aligned, as shown in FIG.4A, in some embodiments. In other embodiments, however, they need not bevertically aligned. Moreover, as was noted, each integrated circuit 100,200, 300 may be a standalone integrated circuit or may be included in awafer. Also, the location of the I/O pads 130, 230, 330 may be differentin the various devices, and may be internal to the wiring layer 120,220, 320 or at an exposed portion of the wiring layer 120, 220, 320. Theintegrated circuits may have a thickness in the range from severalmicrometers to several tens of micrometers in some embodiments. Thefirst integrated circuit 100 may be thicker because it has not yet beensubject to thinning or substrate removal in some embodiments. In otherembodiments, however, it also may be thin.

Referring now to FIG. 4B, a via 402 may be formed by patterning thethird integrated circuit 300, the second integrated circuit 200, and thefirst integrated circuit 100. In some embodiments, the via 402 mayextend through the third integrated circuit 300 and the secondintegrated circuit 200, but only partially through the first integratedcircuit 100, so that a bottom surface of the via 402 may be locatedwithin the first integrated circuit 100. In some embodiments, the floorof the via 402 may be located within the first semiconductor layer 112at a depth that corresponds to the thickness of the second semiconductorlayer 210. However, in other embodiments, the via 402 may penetrate lessdeep or deeper into the first semiconductor layer 112 or may penetrateentirely through the first semiconductor layer 112.

As also shown in FIG. 4B, the via 402 may also penetrate the first,second and third I/O pads 130, 230 and 330, respectively, and may be ofsmaller diameter than the length or width of these pads. In someembodiments, the via 402 may be formed by dry etching, such as byreactive ion etching and/or other conventional techniques. In otherembodiments, a laser may be used to form the via 402. It will beunderstood that, although embodiments of FIG. 4B illustrate formation ofa single via 402, a plurality of vias 402 may be formed in otherembodiments using dry etching, laser etching and/or other techniques.

Referring now to FIG. 4C, the sidewalls of the semiconductor layers arerecessed relative to the wiring layers. In particular, as shown in FIG.4C, the sidewalls of the first semiconductor layer 112, the secondsemiconductor layer 210, and the third semiconductor layer 310 arerecessed, for example by wet etching the structure through the via 402.An etchant that selectively etches the semiconductor layers 112, 210,310 relative to the wiring layers 120, 220, 320 may be used. Forexample, conventional SC1 etchant may be used.

Then, referring to FIG. 4D, an insulating layer 440 may be formed on theexposed portions of the structure. The insulating layer 440 may beformed at relatively low temperature, for example at a temperature lessthan about 400° C. using a chemical vapor deposition method usingplasma, referred to herein as “low temperature plasma oxide deposition”.The growth or deposition of the insulating layer 440 may be faster onthe semiconductor layers 112, 210 and 310 relative to the wiring layers120, 220, 320, due to, for example, a higher growth rate on silicon thanon silicon dioxide. Thus, the insulating layer 440 may be thicker on thesidewalls of the semiconductor layers 112, 210 and 220 than on thesidewalls of the wiring layers 120, 220, 320. In some embodiments, theinsulating layer 420 may comprise silicon dioxide, silicon oxynitrideand/or silicon nitride. However, other materials also may be used,and/or other fabrication techniques may be used.

Referring now to FIG. 4E, anisotropic etching may be performed on theresultant structure, so as to remove the insulating layer 440 from thesidewalls of the wiring layers 120, 220, 320. Insulating layers 140, 240and 340 may remain on sidewalls of the semiconductor layers 112, 210 and310, respectively. In other embodiments, however, some of the insulatinglayer 440 may also remain on the sidewalls of the wiring layers 120,220, 320, as long as the sidewalls of the pads 130, 230, 330 areexposed.

Referring now to FIG. 4F, a monolithic conductive via 400, also referredto as a “conductive electrode”, is then formed to fill the via 402.

The conductive electrode 400 may be formed of the same material that isused to form the pads 130, 230, 330, in some embodiments. For example,copper (Cu) and/or aluminum (Au) may be used. The conductive electrode400 may be formed using chemical vapor deposition (CVD) to fill the via402, followed by planarization to remove the metal from outside the via.In other embodiments, the conductive electrode may be formed usingphysical vapor deposition (PVD), chemical vapor deposition (CVD) platingand/or direct electrode implantation.

Still referring to FIG. 4F, the bottom surface of the firstsemiconductor layer 112 may then be etched, if necessary, to expose theconductive via 400 and produce the structure of FIG. 1. The structurethen may be singulated into multiple stacked structures using a laser,saw and/or other conventional techniques. The three-dimensional stackedintegrated circuits may then be mounted on a printed circuit board orother packaging substrate.

FIGS. 5A and 5B are cross-sectional views of other microelectronicpackages that include linear monolithic conductive vias according tovarious other embodiments during intermediate fabrication stepsaccording to various other embodiments. More specifically, referring toFIG. 5A, a structure may be formed as was described in connection withFIGS. 4A-4C. Then, heat treatment may be performed in an oxidizing ornitridizing environment, to oxidize or nitridize the semiconductorlayers 112, 210 and 310 to form insulating layers 142, 240 and 340 inthe via 402. If the I/O pads 130, 230, 330 are oxidized or nitridized,an additional process may be performed to remove theoxidization/nitridation on the I/O pads 130, 230, 330.

In other embodiments, the first, second and third semiconductor layers112, 210 and 310 may be recessed before performing the heat treatment.

Then, referring to FIG. 5B, anisotropic etching may be performed so asto remove a portion of the insulating layer 142 on the floor of the via402. In other embodiments, the insulating layer 142 on the floor of thevia 402 need not be removed, but may be retained or removed later, ifdesirable. A conductive electrode may then be formed, as was describedin connection with FIG. 4F.

FIGS. 6A and 6B are cross-sectional views of yet other microelectronicpackages that include linear monolithic conductive vias according to yetother various embodiments during intermediate fabrication stepsaccording to yet other various embodiments. In particular, operations ofFIGS. 4A-4C may be performed. Then, a photosensitive material 442 may beformed in the via hole 402, and may be exposed to light (hν) to developthe exposed portions. Portions of the photosensitive layer 442 that arelocated in the recesses of the semiconductor layers may not be exposedby the light and developed. It will be understood that thephotosensitive material 442 may include photoresist, photosensitivepolyimides and/or insulating photosensitive material.

Then, referring to FIG. 6B, the developed portions of the photoresistmay be selectively removed, so as to form the insulating layers 140, 240and 340 from the remaining photosensitive layer.

FIGS. 7A-7E are cross-sectional views of still other microelectronicpackages that include linear monolithic conductive vias according tovarious embodiments during intermediate fabrication steps according tostill other embodiments. Embodiments of FIGS. 7A-7E may correspond toembodiments of FIGS. 4A-4F in certain aspects. Accordingly, for the sakeof brevity, the common aspects will not be repeated, and the differenceswill be highlighted.

Referring to FIG. 7A, the first integrated circuit 500 may include asubstrate insulating layer 514, a device layer 516 and a wiring layer518 that are formed on a semiconductor substrate 512. Thus, layers 512,514 and 516 comprise the semiconductor layer. The wiring layer 518 mayinclude an I/O pad 530. The pads 230, 330 and 530 may be verticallyaligned in some embodiments.

Referring now to FIG. 7B, a via 502 may be formed to penetrate thewiring layer 518 and the device layer 516 of the first integratedcircuit 500, but may not penetrate the insulating layer 514 or thesemiconductor substrate 512. However, in other embodiments, the via 502may not fully penetrate the device layer 516 or the wiring layer 518.Moreover, in other embodiments, the via 502 may also penetrate theinsulating layer 514 and/or the semiconductor substrate 512, and, insome embodiments, may extend therethrough. The via may be formed by dryetching, laser etching and/or other techniques.

Referring now to FIG. 7C, recesses may be formed using, for example, wetetching as was described above in connection with FIG. 4C.

Referring now to FIG. 7D, an insulating layer 540 may be formed similarto the insulating layer 440 of FIG. 4D.

Referring to FIG. 7E, the insulating layer 540 is then anisotropicallyetched to form the insulating layers 542, as was described in connectionwith FIG. 4E.

Then, a conductive electrode may be formed in the via 502 and thesemiconductor substrate 512, and the insulating layer 514 may beremoved, as was described in connection with FIG. 4F.

FIGS. 8A-8E are cross-sectional views of microelectronic packages thatinclude stepped vias according to various embodiments duringintermediate fabrication steps according to various embodiments.

Referring to FIG. 8A, a structure 50 may include a first integratedcircuit 1000 and a second integrated circuit 1100 that are sequentiallystacked. The first integrated circuit 1000 may include a firstsemiconductor layer 1012 and a first wiring layer 1020 having a firstI/O pad 1030 therein. The second integrated circuit 1100 may include asecond semiconductor layer 1100 and a second wiring layer 1120 includinga second I/O pad 1130 therein. As shown in FIG. 8A, the first and secondI/O pads 1030 and 1130 may be offset from each other. The compositionand numbers of the integrated circuit devices 1000 and 1100 may vary asdescribed in the above embodiments and will not be described again forthe sake of brevity. In some embodiments, the first and secondintegrated circuits 1100 and 1110 may be the same functional device,except for the relative positions of the I/O pads 1030 and 1130. Inother embodiments, different types of integrated circuits may beprovided. As also shown, the I/O pads 1030 and 1130 may have an equallength L and may be offset by a distance D. In other embodiments,however, the lengths need not be the same, as long as the edges of thepads are offset from one another.

Referring now to FIG. 8B, a first mask 1161 is formed on the structureusing, for example, photoresist. The first mask 1161 is then patterned.The removed portion of the first mask 1161 may correspond to a portion1130 a of the second pad 1130, and a portion 1030 a of the first pad1030, and a portion of the semiconductor layer 1012 where the pad 1030is not located. A via 1202 is then formed using the first mask 1161 andthe exposed portions 1030 a and 1130 a of the first and second I/O pads1030 and 1130, respectively, as etch stops. Thus, the via 1202 mayextend vertically at the boundaries of the pads 1130 and 1030. Moreover,as shown in FIG. 8B, the via 1202 may also penetrate at least partwayinto the first semiconductor layer 1012. In other embodiments, the via1202 may penetrate entirely through the layer 1012. Thus, in embodimentsof FIG. 8B, a single photoresist pattern 1161 may be used in combinationwith the first and second I/O pads 1030 and 1130 acting as etch stoplayers. Thus, a stepped via 1202 may be formed that recesses a sidewallof the second integrated circuit 1100 relative to a sidewall of thefirst integrated circuit 1000, so as to expose a portion 1030 a of thewiring on the face of the first integrated circuit 1000.

Referring now to FIG. 8C, an insulating layer 1240 may be conformallyformed on the exposed portion of the via 1202. The insulating layer 1240may comprise silicon oxide, silicon nitride, polymer and/or otherinsulating layers.

Referring now to FIG. 8D, the structure is then anisotropically etchedso as to form an insulating layer 1040 on sidewalls of the via 1202. Insome embodiments, the insulating layer 1040 may be formed on sidewallsof the semiconductor layers 1012, 1110 and the wiring layers 1020 and1120. The insulating layer 1040 may be removed from horizontal surfaces,so as to expose the portions 1030 a, 1130 a of the I/O pads 1030, 1130.

Referring now to FIG. 8E, a conductive layer is formed in the via 1202and on the surface of the structure, and may then be planarized to forma monolithic conductive electrode 1400. The monolithic conductiveelectrode 1400 electrically contacts the exposed portions 1030 a, 1130 aof the I/O pads 1030 and 1130. Then, the bottom surface of the firstsemiconductor layer 1012 may be polished or otherwise etched to exposethe monolithic conductive electrode 1400. Dicing and further packagingmay then take place, as desired.

FIGS. 9A-9C are cross-sectional views of other microelectronic packagesthat include stepped vias according to various embodiments duringintermediate fabrication steps according to still other embodiments. Inthese embodiments, the stepped via 1202 is formed using multiple maskingsteps rather than a single masking step.

In particular, as shown in FIG. 9A, a portion of the semiconductor layer1012 of the first integrated circuit 1000 may be removed by etchingusing a first photoresist mask 1163 to form a first via 1204. The firstvia 1204 is not formed over the I/O pads 1030 or 1130.

Then, referring to FIG. 9B, a second via 1206 is formed to expose aportion 1030 a of the first I/O pad 1030 using a second mask 1165. Theexposed portion 1030 a acts as an etch stop.

Then, referring to FIG. 9C, a third photoresist pattern 1167 may beformed above a portion 1130 a of the second I/O pad 1130. A third via1208 is then formed using the third photoresist pattern 1167 as an etchmask and the exposed portion 1130 a as an etch stop. Thus, a stepped via1202 is formed that includes the first, second and third vias 1204, 1206and 1208. Subsequent processing may occur as was described in FIGS.8C-8E.

FIG. 10 is a cross-sectional view of a microelectronic package accordingto still other embodiments. Referring to FIG. 10, this package includesfirst, second and third integrated circuits 710, 720 and 730 that eachinclude a semiconductor layer 712, 722, 732 and a wiring layer 714, 724,734, respectively, wherein an I/O pad 716, 726, 736, respectively, isincluded in each wiring layer. A sidewall insulating layer 742 and amonolithic conductive via 740 is also included. The integrated circuits700 are mounted on a mounting substrate 600, which may include a printedcircuit board or other conventional mounting substrate.

The mounting substrate 600 may include an upper surface 622 adjacent theintegrated circuits 700 and a lower surface 624 remote from theintegrated circuits 700. A first package pad 608 a is provided on theupper surface 622 and is electrically connected to a wire 612 thatitself is connected to the conductive via 740. The first package pad 608a may comprise copper (Cu), aluminum (Al), nickel (Ni), platinum (Pt),silver (Ag) and/or gold (Au). The first package pad 608 a may be closeto an edge of the mounting substrate 600. Moreover, a second package pad608 b may be provided in an insulating layer 604 that is on the uppersurface 622 of the mounting substrate 600. A plurality of second packagepads 608 b may be provided in an array at regular intervals in a rowparallel to an edge of the mounting substrate 600 and/or in otherarrangements.

A plurality of outer package pads 606 may be provided in an insulatinglayer 602 on the bottom surface 624 of the mounting substrate 600. Oneor more connection terminals 610 may be disposed on the lower surface624 and electrically connected to the outer package pads 606. Theconnection terminals 610 may be solder balls or solder bumps forconnection with an external device, and may comprise gold (Au), lead(Pb), silver (Ag), nickel (Ni), copper (Cu) and/or tin (Sn) alloys. Forexample, the connection terminal 610 may comprise Cu—Ni—Pb, Cu—Ni—Au,Cu—Ni, Ni—Au and/or Ni—Ag. The outer package pads 606 may haverelatively good conductivity and may comprise copper (Cu), aluminum(Al), nickel (Ni), platinum (Pt), silver (Ag) and/or gold (Au).

In some embodiments, the integrated circuits 710, 720 and 730 may bememory integrated circuits that include a peripheral circuit region anda cell region. The integrated circuits 710, 720 and 730 may include anonvolatile memory, a random access memory and/or other memories, suchas a flash memory chip, a PRAM chip, an SRAM chip, and MRAM chip and/ora DRAM chip.

It will be understood that the various internal and external connectionsshown in FIG. 10 may be varied considerably. For example, in embodimentsof FIG. 10, a lower end of the left conductive via 740 is connected to asecond package pad 608 b and an upper end of the right conductive via740 is connected to a first package pad 608 a by a wire 612. However,many other configurations of connections may be provided in otherembodiments. An encapsulation or mold layer 614 may be used to seal theentire microelectronic package and the connection wire 612.

FIG. 11 is a block diagram of a card that may be embodied usingmicroelectronic packages according to various embodiments. For example,a memory card 2800 includes a memory device 2820 and a controller device2810 that exchange data and commands therebetween and communicate withexternal devices through external input/output connectors 2830. Inembodiments of FIG. 11, the card 2800 may be embodied as shown in FIG.10, with the controller 2810 being the first integrated circuit 710, thememory 2820 being the second and third integrated circuits 720 and 730,and the input/output connectors being the connection terminals 610. Manyother configurations may be provided.

FIG. 12 is a block diagram of other embodiments of the presentinvention, wherein an electronic system 3000 includes a processor 3010,a memory 3020 and an input/output system 3030 that are interconnected bya bus 3040. Embodiments of FIG. 12 may be embodied as shown in FIG. 10,such that the processor 3010 corresponds to the first integrated circuit710, the memory 3020 corresponds to the second integrated circuit 720and the input/output controller 3030 corresponds to a third integratedcircuit 730. The bus 3040 may be embodied by the conductive electrodes740. Many other configurations may be provided.

Many different embodiments have been disclosed herein, in connectionwith the above description and the drawings. It will be understood thatit would be unduly repetitious and obfuscating to literally describe andillustrate every combination and subcombination of these embodiments.Accordingly, the present specification, including the drawings, shall beconstrued to constitute a complete written description of allcombinations and subcombinations of the embodiments described herein,and of the manner and process of making and using them, and shallsupport claims to any such combination or subcombination.

In the drawings and specification, there have been disclosed embodimentsof the invention and, although specific terms are employed, they areused in a generic and descriptive sense only and not for purposes oflimitation, the scope of the invention being set forth in the followingclaims.

What is claimed is:
 1. A microelectronic package, comprising: a plurality of integrated circuits that are stacked upon one another, a respective integrated circuit including a semiconductor layer having microelectronic devices therein and a wiring layer on the semiconductor layer having wiring that selectively interconnects the microelectronic devices; and a monolithic conductive via that extends through the plurality of integrated circuits including through the semiconductor layers and through the wiring layers thereof, the monolithic conductive via selectively electrically contacting the wiring, wherein the semiconductor layers include recessed sidewalls relative to the wiring layers, the microelectronic package further comprising an insulating layer between the recessed sidewalls and the monolithic conductive via.
 2. A microelectronic package according to claim 1 wherein the plurality of integrated circuits are directly attached to one another without an intervening glue layer.
 3. A microelectronic package according to claim 1 wherein the plurality of integrated circuits comprise a plurality of integrated circuit wafers that are stacked upon one another.
 4. A microelectronic package according to claim 1 wherein the wiring includes input/output pads and wherein the monolithic conductive via selectively electrically contacts the input/output pads.
 5. A microelectronic package according to claim 1 wherein the plurality of integrated circuits comprise a memory integrated circuit, a memory controller integrated circuit, a processor integrated circuit and/or an input/output controller integrated circuit.
 6. A microelectronic package, comprising: a plurality of integrated circuits that are stacked upon one another, a respective integrated circuit including a semiconductor layer having microelectronic devices therein and a wiring layer on the semiconductor layer having wiring that selectively interconnects the microelectronic devices; and a monolithic conductive via that extends through the plurality of integrated circuits including through the semiconductor layers and through the wiring layers thereof, the monolithic conductive via selectively electrically contacting the wiring, wherein the plurality of integrated circuits comprises a first and a second integrated circuit that are stacked upon one another such that the wiring layer of the first integrated circuit is adjacent the semiconductor layer of the second integrated circuit; wherein a sidewall of the semiconductor layer of second integrated circuit is recessed relative to a sidewall of the wiring layer of the first integrated circuit so as to expose a portion of the wiring of the first integrated circuit; and wherein the monolithic conductive via is a stepped monolithic conductive via that electrically contacts the portion of the wiring of the first integrated circuit.
 7. A microelectronic package according to claim 6 further comprising an insulating layer between the sidewalls of the first and second integrated circuits and the monolithic conductive via.
 8. A microelectronic package according to claim 6 wherein the plurality of integrated circuits comprise a plurality of integrated circuit wafers that are stacked upon one another.
 9. A microelectronic package, comprising: a plurality of integrated circuits that are stacked upon one another, a respective integrated circuit including a semiconductor layer having microelectronic devices therein and a wiring layer on the semiconductor layer having wiring that selectively interconnects the microelectronic devices; and a monolithic conductive via that extends through the plurality of integrated circuits including through the semiconductor layers and through the wiring layers thereof, the monolithic conductive via selectively electrically contacting the wiring, wherein the plurality of integrated circuits are directly attached to one another by oxygen bonds.
 10. A microelectronic package according to claim 9 wherein the plurality of integrated circuits comprise a plurality of integrated circuit wafers that are stacked upon one another. 